Component mounting arrangement

ABSTRACT

A method of connecting a component to a molded article may include disposing a component adjacent to a wall of the article being molded, overlapping a portion of the component with a portion of the wall of the article being molded while the wall is still at least partially molten, and permitting the wall of the article being molded to cool with said portion of the component still overlapped by the wall. Preferably, a portion of the component is overlapped on two sides by the wall of the article being molded to firmly retain the component relative to the article after the article is formed. The article may be a receptacle, or any other object, as desired.

REFERENCE TO COPENDING APPLICATION

This application is a divisional of U.S. application Ser. No. 12/964,178filed Dec. 9, 2010 and claims the benefit of U.S. Provisionalapplication Ser. No. 61/285,700 filed Dec. 11, 2009, which areincorporated herein by reference in their entirety.

TECHNICAL FIELD

The present disclosure relates generally to an arrangement for mountinga component relative to another component.

BACKGROUND

Receptacles may include components within their interior volume, orconnected to their exterior. For example, fuel tanks for vehiclestypically include a fuel pump, one or more valves, a fuel level sensorand perhaps other components arranged within the fuel tank. Thecomponents may be mounted on a carrier or other support that is placedin the fuel tank, or the components may be attached to a flange that issecured on an already formed fuel tank wall, such as by a clamp orthreaded connection.

SUMMARY

A method of connecting a component to a molded article may includedisposing a component adjacent to a wall of the article being molded,overlapping a portion of the component with a portion of the wall of thearticle being molded while the wall is still at least partially molten,and permitting the wall of the article being molded to cool with saidportion of the component still overlapped by the wall. Preferably, aportion of the component is overlapped on two sides by the wall of thearticle being molded to firmly retain the component relative to thearticle after the article is formed. The article may be a receptacle, orany other object, as desired.

A method of forming a molded article with a component attached to thearticle may include several steps, including:

providing a molten parison into a mold cavity defined by at least twomolds;

forming the parison into the mold cavity;

severing at least a portion of the parison;

separating at least two of the molds to also separate portions of thesevered parison and expose an interior of the parison;

disposing a component adjacent to a wall of the parison;

overlapping a portion of the component with a portion of the wall of theparison while the wall is still at least partially molten; and

closing said at least two of the molds to define an enclosed mold cavityand join together again the severed portions of the parison. In thisway, the parison can be opened to permit one or more components to bereceived within an interior of the parison and closed to seal thesevered portions of the parison together for final forming or curing.

In one form, a system for attaching a component to a receptacle mayinclude a mold defining part of a forming surface against which thereceptacle is molded, and at least one tool cavity open to the formingsurface, a tool disposed at least partially within the tool cavity andmovable relative to the forming surface from a retracted position to anadvanced position. The tool may have a working surface that engagesmaterial forming the receptacle at least when the tool is moved to itsadvanced position to overlap a portion of the component with materialforming the receptacle to hold said component in position relative tothe receptacle.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description of exemplary embodiments and bestmode will be set forth with reference to the accompanying drawings, inwhich:

FIG. 1 is a cross-sectional view of one exemplary implementation of ablow molding apparatus that may be used to form a receptacle;

FIG. 2 is a cross-sectional view of the blow molding apparatus of FIG. 1illustrating a component positioned between separated halves of theparison and blow mold, and being connected to the parison;

FIG. 3A is an fragmentary side view, partially in section, showing acomponent within a recess of a mold, and tools prior to engaging theparison;

FIG. 3B is a view similar to FIG. 3A, showing tools engaging the parisonto overlap a portion of the component with the parison;

FIG. 4 is a fragmentary sectional view of one exemplary parisonconstruction;

FIGS. 5-10 are diagrammatic plan views showing different exemplaryimplementations of tools; and

FIGS. 11 and 12 are diagrammatic plan views showing differentimplementations of a component.

Detailed Description of Presently Preferred Embodiments

Referring in more detail to the drawings, FIG. 1 illustrates a blowmolding apparatus 10 that may be used to form an article from a moltenparison 12. In one implementation, the article may be a receptacle, suchas a fuel tank used in a vehicle fuel system. Of course, the receptaclecould be used to contain something other than fuel. In the example of afuel tank, the fuel tank may include one or more walls 14 defining aninternal volume 16 in which the fuel is contained. The fuel tank wall(s)14 may be formed of any suitable material(s). In one form, the fuel tankmay be formed from several layers of polymeric materials, in a so-called“multi-layer” fuel tank. As shown in FIG. 4, the various layers mayinclude one or more structural layers which may form inner and outerlayers 17, 18 formed of HDPE or the like, one or more adhesive layers 20and one of more barrier layers 22 having a desired resistance topermeation therethrough of hydrocarbon or other vapors or liquidsassociated with the fluid contained within the fuel tank. Exemplarybarrier layer materials include nylons and EVOH (ethylene vinylalcohol), although others may be used. Alternatively, the tank could beformed from a single material, or could have layers in addition to orother than those specifically noted herein.

In forming a hollow receptacle such as a fuel tank, the parison may beintroduced into a blow mold apparatus 10 having a mold cavity defined byone or more molds 24, 26 collectively defining a forming surface 28against which the parison 12 is inflated by introduction of pressurizedgas through a blow pin 30. In one implementation, the apparatus andmethod set forth in U.S. patent application Ser. No. 12/491,964 filed onJun. 25, 2009, could be utilized, and the disclosure of that applicationis incorporated herein by reference in its entirety. In general, theparison 12 may be initially blow molded, than separated into two halves,such as by suitable cutters 32. The molds 24, 26 with the severedparison halves therein, can then be opened, as shown in FIG. 2. In thisposition, components can be inserted between the separated mold andparison halves, prior to joining together again the parison halves tofinally form the receptacle. In this manner, various components 34 canbe disposed within an interior volume of the receptacle, or, withappropriate modification of the molds 24, 26, could be disposed on orotherwise carried by an exterior of the receptacle.

In one implementation, as shown in FIGS. 2, 3A and 3B, at least oneportion of the mold 24, 26 includes a recess 36 adapted to receive atleast a portion of a component 34 to be connected to the receptacle. Themold 24, 26 may also include one or more openings or tool passages 38that are open to the recess 36. The recess 36 may be formed in theforming surface 28 of the mold, and may define part of the formingsurface of the mold. The tool passages 38 may be formed through the mold24, 26 so that they open directly (or axially) to the interior of themold. Or, as shown in FIGS. 3A and 3B, the tool passages 38 may be blindbores or otherwise terminate to open generally radially to the recess 36and may define an inwardly extending flange 40, as shown in

FIGS. 3A and 3B. In this form, the tool passages 38 may be formed froman opposite side of the mold 24, 26 as the forming surface 28, and mayoverlap, or intersect, or otherwise open or be opened into the recess36. The recess 36 may be formed by a right cylindrical blind bore, or ofany other shape and orientation, and the tool passages 38 may be formedby a straight bore open and parallel to the recess. Of course, otherarrangements may be used.

In one implementation, such as shown in FIGS. 2, 3A and 3B, a component34 may include an end surface 37 and a radially outwardly extendingflange 42 that defines part of an undercut, recess or void 44 adjacentto the flange. The component 34 may include a second flange 46 or othersurface that defines a neck 48 between the two flanges 42, 46. Therecess 36 in the mold 24, 26 may be sufficiently deep to enable theflange 42 to be at least partially received in the recess 36 andposition the void 44 of the component 34 at least partially in therecess 36. The component 34 could have substantially any shape. Somerepresentative shapes are shown, for example, in FIGS. 3, 11 and 12, butmany others are possible. The flange 42 need not be circumferentiallycontinuous. Indeed, no flange 42 or 46 need be provided. The void 44provided in the component 34 in which the parison material is at leastpartially moved, need not be circumferentially continuous or extend allthe way around the component. Rather, the void could include one or morecavities, undercuts, grooves, slots or the like, which could be providedin the component to receive some of the parison material as movedtherein by the tools. And such voids can be spaced apart about theexterior of the component in any desired arrangement.

One or more tools 50 may be disposed in the tool passage 38 (orpassages), adjacent to the recess 36, and movable relative to the recess36. Each tool 50 may include an arm 52 and a working end 54 carried bythe arm 52 and adapted to engage the parison 12. The tools 50 may bemoved from a first position, retracted away from the component as shownin FIG. 3A, and a second position advanced toward the component as shownin FIG. 3B. The tools 50 may be driven between and to their retractedand advanced positions by one or more actuators 56. Of course, the tools50 can be manually manipulated. The tools 50 may be driven along alinear path generally perpendicular to an axis 58 of the recess 36, orthey may be driven along any suitable path between retracted andadvanced positions as generally discussed above (for example, they maybe pivoted along an arcuate path, rotated or some combination ofmultiple paths of movement, if desired).

As best shown in FIGS. 3A and 3B, insertion of the component 34 into therecess 36 engages the end surface 37 of the component with the parisonand may also displace the adjacent portion of the parison 12, which isstill at least partially molten and pliable, into the recess 36 and nextto the tools 50. Thereafter, when the tools 50 are advanced from theirrefracted position, shown in FIG. 3A, to their advanced position, shownin FIG. 3B, a portion of the parison 12 is moved against the component34 and/or into the void(s) 44 of the component 34 by the tools 50 sothat a portion of the component 34 is overlapped by a portion of theparison wall 12. That is, a portion of the parison wall is folded over aportion of the component so that at least a portion of the component 34is sandwiched or trapped between two portions of the parison wall, withthe parison wall disposed adjacent opposed surfaces or sides of the wallof the component. The parison material may be sufficiently heated toaffect a bonding or welding of the parison material to the material ofthe component 34 which may be formed of a suitably compatible polymericmaterial. Of course, such welding or bonding may not be necessary toeffectively connect the component 34 to the parison 12 and finallyformed receptacle in view of at least the manner in which the parisonwall is overlapped about the component.

Upon final forming and cooling of the parison 12, the component 34remains at least partially trapped or overlapped by the parison wall toretain the position of the component 34 relative to the finishedreceptacle. Again, in the implementation shown in FIGS. 2, 3A and 3B,the component 34 is attached adjacent to an interior surface of theparison wall 12 so that the component 34 extends into and communicateswith the internal volume of the receptacle. After a desired time intheir advanced position, the tools 50 are moved to their retractedposition so that the working ends 54 of the tools 50 are clear of theparison 12 and the component 34 to permit removal of the parison 12,with the component 34 attached thereto, from the recess 36 and the mold24, 26. The parison halves can then be joined together, such as bywelding, to form the receptacle or other article, or, the parison halvescan be joined before the tools 50 are moved to their retracted position,or at any other time.

As shown in FIGS. 5 and 6, one or more tools 50 may be provided todisplace portions of the parison relative to the component, to movespaced apart portions of the parison into one or more voids of thecomponent to more securely connect the component to the parison. Whiletwo and three tools 50 are shown, substantially any number of tools 50may be used as desired to effect a connection between the component 36and the parison 12. The tools 50 may be evenly or unevenlycircumferentially spaced, as desired. FIGS. 7-9 illustrate tools havingdifferently shaped working ends 54 or surfaces which may displace theparison material in different manners relative to the component. Anydesired shape of the working ends 54 may be used in addition to usingany desired number of tools to provide a desired movement of the parisonmaterial and entrapment of the component 34 in the parison material. Inusing tools 50 with differently shaped end surfaces, only a very minorportion of the component may be overlapped by the parison material, orsubstantially all of the flange (or other portion of the component) maybe trapped within the parison material, as desired. Still further, FIG.10 illustrates that the working ends 54 may have a different shape orconfiguration in a generally axial direction, that is, they may havegreater thickness to move a greater axial length of the parison materialrelative to the component as compared to a relatively thin, flat workingsurface. In this way, the component 34 and the tool(s) 50 can beconstructed in a wide variety of configurations and arrangements tofacilitate attaching the component to the parison wall during themolding process.

Accordingly, a method of connecting a component to a molded article, mayinclude disposing a component adjacent to a wall of the article beingmolded, folding a portion of the parison wall over a portion of thecomponent while the wall is still at least partially molten, andpermitting the wall of the article being molded to cool with a portionof the component still overlapped by the wall. The molded article can beof substantially any shape and arrangement and need not be hollow orentirely hollow. The description of the exemplary blow-molded receptacleis not intended to limit the applications and arrangements to which themethod and apparatus can be applied. The component can take many forms,include a bracket or other device that merely supports anothercomponent.

While the forms of the invention herein disclosed constitute presentlypreferred embodiments, many others are possible. For example, a recess36 in the mold 24, 26 may not be needed. If no recess 36 is provided,the tools 50 may be initially retracted until the component is disposedadjacent to the parison wall, and then the tools may be advanced towardthe component to move portion of the parison wall around an edge of thecomponent and then inwardly to fold the material into a void or aroundan edge of the component. Thereafter, the tool may be retracted to itsinitial position. The tool may advanced and retracted linearly (e.g. afirst linear movement forward and a second linear movement inward towardthe component), along a pivoted or arcuate path, or in any othersuitable way. It is not intended herein to mention all the possibleequivalent forms or ramifications of the invention. It is understoodthat the terms used herein are merely descriptive, rather than limiting,and that various changes may be made without departing from the spiritor scope of the invention.

1. A method of connecting a component to a molded article, comprising:disposing a component adjacent to a wall of the article being molded;overlapping a portion of the component with a portion of the wall of thearticle being molded while the wall is still at least partially molten,so that at least a portion of the component is received between twoportions of the wall to connect the component to the wall; andpermitting the wall of the article being molded to cool with saidportion of the component still overlapped by the wall to maintain theconnection of the component to the wall.
 2. The method of claim 1wherein overlapping a portion of the component with a portion of thewall is accomplished by moving at least one tool relative to thecomponent so that the tool engages a portion of said wall and moves saidportion of the wall until said portion of the wall overlaps a portion ofthe component.
 3. The method of claim 1 wherein the component includes avoid and the portion of the wall is moved at least partially into thevoid during the overlapping step to connect the component to the wall.4. The method of claim 1 wherein the component includes a flange and theportion of the wall is folded around the flange so that portions of thewall overlies two opposed sides of the flange and the flange is trappedbetween said portions of the wall.
 5. The method of claim 2 wherein saidat least one tool includes at least two spaced apart tools each adaptedto move relative to the component a different portion of the wall of thearticle.
 6. The method of claim 1 wherein disposing a component adjacentto a wall of the article being molded is accomplished by pressing an endsurface of the component against the wall and displacing a portion ofthe wall and overlapping a portion of the component with a portion ofthe article being molded is accomplished after said end surface of thecomponent is pressed against the wall.
 7. A system for attaching acomponent to a receptacle, comprising: a mold defining part of a formingsurface against which the receptacle is molded, and at least one toolcavity open to the forming surface; and a tool disposed at leastpartially within the tool cavity and movable relative to the formingsurface from a retracted position to an advanced position, the toolhaving a working surface that engages material forming the receptacle atleast when the tool is moved to its advanced position to overlap aportion of the component with material forming the receptacle to holdsaid component in position relative to the receptacle.
 8. The system ofclaim 7 wherein the mold includes a recess defining part of a formingsurface against which the receptacle is molded, and said tool cavity isopen to the recess with the tool moveable within the tool cavity andrelative to the recess to move material against a portion of thecomponent to hold said component in position relative to the receptacle.9. The system of claim 8 wherein the recess is sized to receive an endsurface of the component therein, with material forming the receptacledisposed adjacent to the end surface and within the recess.